System and method for forming an interlocking solar panel array

ABSTRACT

A mounting system for supporting solar panel cells above a support surface. The system may have a frame including a plurality of frame sections that are secured to a solar panel cell. At least one of the frame sections may include a pair of walls forming a first channel for receiving an edge portion of the solar panel cell, and a second channel spaced apart from the first channel. The second channel may have a curving inner wall. The at least one frame section may also have a base portion. The mounting system may also include a mounting bracket having a pair of flanges and forming a third channel therebetween. One of the flanges of the third channel may form a curving flange. The curving flange and the second channel of the frame section may cooperatively secure the frame section and the mounting bracket together.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application claims priority from U.S. Provisional Patent Application Ser. No. 61/145,653, filed Jan. 19, 2009, the entire contents of which are hereby incorporated by reference into the present application.

FIELD

The present disclosure relates to solar panel arrays, and more particularly to a system and method for supporting a plurality of independent solar panel modules adjacent to one another and interlocking the modules to form a solar panel array.

BACKGROUND

The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.

Solar panel systems are growing in popularity and interest at the present time. A solar panel array is typically formed by a plurality of independent solar panel modules that are positioned closely adjacent to one another. The modules may be coupled to frame sections so that they are fixedly secured relative to one another after the installation is complete. If only a few modules are used, then they may be arranged in a single row. However, in medium and large scale installations involving dozens or even hundreds or more independent modules, then the modules will typically be arranged in a grid of rows and columns.

Typically the independent solar panel modules each are formed by a solar panel cell that is supported with a frame structure. Typically a plurality of brackets is fixedly attached at one end thereof to the frame with independent fasteners, and the other ends of the brackets are secured either to a support base or possibly directly to a roof of a structure or residence. In either event, the need to attach the brackets manually with fastening elements adds significantly to the time required to install a solar panel array. Since the labor cost in installing a solar panel array can be significant, there is a strong interest in simplifying and expediting the manner in which a solar panel assembly is attached to a roof of a building or residence or other support structure.

SUMMARY

In one aspect the present disclosure relates to a mounting system for supporting solar panel cells above a support surface. The system may comprise a frame including a plurality of frame sections that are secured to a solar panel cell. At least one of the frame sections may include a pair of walls forming a first channel for receiving an edge portion of the solar panel cell, and a second channel spaced apart from the first channel. The second channel may have a curving inner wall. The at least one frame section may also have a base portion. The mounting system may also include a mounting bracket having a pair of flanges and forming a third channel therebetween. One of the flanges of the third channel may form a curving flange. The curving flange and the second channel of the frame section may cooperatively secure the frame section and the mounting bracket together.

In another aspect the present disclosure relates to a mounting system for supporting solar panel cells panels above a support surface. The mounting system may comprise a frame including a plurality of frame sections that are secured to extend around a periphery of a solar panel cell. At least one of the frame sections may include a pair of walls forming a first channel for receiving an edge portion of the solar panel cell, and a second channel spaced apart from the first channel, with the second channel having a curving inner wall. The mounting system may also include a mounting bracket having a curving flange shaped generally in accordance with the curving inner wall. The curving flange and curving inner wall cooperatively enable the frame to be oriented non-perpendicular to the mounting bracket when the curving flange is initially inserted into the second channel, and then enable the frame to be rotated into a position generally perpendicular to the mounting bracket.

In still another aspect the present disclosure relates to a frame adapted to support a solar panel cell. The frame may include a plurality of frame sections adapted to be secured around a perimeter of the solar panel cell. At least one of the frame sections may include a first channel for engaging with an edge portion of the solar panel cell, and a second channel having a curving inner wall. The curving inner wall permits the at least one frame section to be initially engaged with the mounting bracket in an orientation nonperpendicular to the mounting bracket, and then rotated into a position generally perpendicular to the mounting bracket, in which the mounting bracket is then captured in the second channel.

In still another aspect the present disclosure relates to a mounting bracket for supporting a frame of a solar panel cell above a support surface. The mounting bracket may include a channel having a pair of flanges forming a channel therebetween, wherein the channel receives therein a frame section of the solar panel cell frame when the mounting bracket is coupled to the frame section. One flange of the pair of flanges may have a curving shape that permits the frame section to be engaged in the channel in an orientation non-perpendicular to the mounting bracket, and then pivoted into a position generally perpendicular to the mounting bracket so that the frame section is captured in the channel of the mounting bracket.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.

FIG. 1 is a perspective view of a solar panel array disposed on a roof of a structure;

FIG. 2 is a plan view of one solar panel module illustrating the four frame sections that make up the frame;

FIG. 3 is a side view of an embodiment of one bracket of the present disclosure that is used to assemble the solar panel plan modules into an array;

FIG. 4 is a side view of an embodiment of another bracket of the present disclosure to assemble the solar panel modules into an array;

FIG. 5 is a side view of an embodiment of still another bracket of the present disclosure that is used to assemble the solar panel module into an array;

FIG. 6 a side view of two solar panel modules being supported by two different ones of the brackets of the present disclosure;

FIG. 6A is an enlarged view of one of the frame sections shown in FIG. 6;

FIG. 7 is a side view showing how one of the solar panel modules may be angled during attachment of one of its frame sections to one of the brackets;

FIG. 8 is a perspective view of one of the modules with all three of the different brackets attached to different ones of its frame sections;

FIG. 9 is a perspective view showing two of the solar panel modules being coupled together;

FIG. 10 is a perspective view showing a third one of the solar panel modules being coupled to two other coupled solar panel modules;

FIG. 11 is a perspective view showing how a fourth solar panel module may be coupled to two other modules; and

FIG. 12 is a perspective view showing how the fourth solar panel module of FIG. 11 is spaced slightly apart from the second solar panel module as it is laid flat with the other three modules, before being slid towards the second module to complete the assembly process.

DETAILED DESCRIPTION

Referring to FIG. 1, there is shown a solar panel array 10 in accordance with one embodiment of the present disclosure. The array 10 in this example includes four rectangular solar panel modules 12 a-12 d, although it will be appreciated that the modules could be square in shape or may be formed in various other shapes as well. Thus, the illustration of rectangular modules 12 is only meant to show one shape that the modules 12 a-12 d may each have. The solar panel array 10 is mounted on a roof 14 of a structure such as a residence or building. However, it will be appreciated that the array 10 could also be mounted close to a ground surface, such as on some type of support base positioned on the side of a hill or mountain.

The modules 12 a-12 d each include a photovoltaic panel in the form of a solar panel cell 16, and a frame 18 that secures to an edge portion of the solar panel cell 16. As shown in FIG. 2, each frame 18 may be comprised of four frame sections 18 a, 18 b, 18 c and 18 d. The frame sections 18 a and 18 b in this example have identical lengths, while the frame sections 18 c and 18 d have identical lengths. The frame sections 18 a-18 d may all be of identical construction and in one embodiment are formed from aluminum. The frame sections 18 a-18 d may be extruded from aluminum or they may be formed in accordance with other manufacturing techniques. However, it is anticipated that extrusion molding is likely to prove to be an especially attractive manufacturing method.

With further reference to FIGS. 6, the cross-sectional construction of frame sections 18 c and 18 d for modules 12 a and 12 b can be seen. It will be appreciated that the construction (i.e., cross-sectional configuration) for each of the frame sections 18 a-18 d is identical in this example, the only difference between the frame sections being that sections 18 a and 18 b are longer than sections 18 c and 18 d in order to form rectangular shaped frames. In view of this, only the construction of frame section 18 d will be discussed, with it being understood that the description applies equally to the other frame sections 18 a, 18 b and 18 c.

Referring to FIG. 6A, frame section 18 d includes an upper channel 20 formed by spaced apart parallel walls 20 a and 20 b. The upper channel 20 has width and depth dimensions that enable it to receive an edge portion of solar panel cell 16. An intermediate channel 22 is formed to open in a direction opposite to channel 20 at an intermediate point along the height of the frame section 18 d. The intermediate channel 22 has a curving inner wall 22 a, the purpose of which will be described in the following paragraphs. The frame section 18 d also has a longitudinal wall portion 23, a back wall 25 and a base 24 that cooperatively define a hollow area 27. Portions 23, 24 and 27 also add significant rigidity to the frame section 18 d. The base 24 has a longitudinally extending groove or angled notch 26 in its lower surface, the purpose for which will be described in the following paragraphs, that may extend the full length of the frame section 18 d. The frame sections 18 a, 18 b, 18 c and 18 d for a given module 12 are all arranged such that the base 24 of each faces inwardly to reside under the solar cell 16 of the module 12 when the frame 18 of each module 12 is fully assembled. The bases 24 may also be miter cut at their joining ends to avoid interference issues.

Referring now to FIGS. 3, 4 and 5, support brackets 30, 32 and 34 are shown. Bracket 30 includes an upper flaring pair of flanges 30 a and a lower pair of flat flanges 30 b that each has a barbed edge 30 c. The bracket 30 also includes a base 30 d having a hole 30 e. Hole 30 e accepts a fastener that may be used to secure the bracket via a threaded fastener to a support base or possibly directly the roof 14. One pair of flanges 30 a and 30 b cooperate to form a channel 30 f while the other pair of flanges cooperate to form a channel 30 g. Raised internal shoulders 30 h provide stops that limit insertion of the frame sections 18 to a predetermined depth within the channels 30 f and 30 g.

Referring to FIG. 4, bracket 32 is similar in construction to bracket 30 but only includes a single upper flaring flange 32 a and a single flat flange 32 b having a barbed edge 32 c. A base portion 32 d has a hole 32 e for receiving a fastener. The flanges 32 a and 32 b cooperatively form a channel 32 f. Internal shoulder 32 h limits the depth of insertion of the frame section 18 that is inserter into the channel 32 f.

Referring to FIG. 5, bracket 34 is also similar in construction to bracket 30 but includes a straight upper flange 34 a 1 and an opposing upwardly flaring flange 34 a 2. A pair of opposing straight flanges 34 b each having a barbed edge 34 c are formed below the flanges 34 a 1 and 34 a 2 to form channels 34 f and 34 g. The bracket 34 also has a base 34 d having a hole 34 e for receiving a fastening element. Raised internal shoulders 30 h limit the depth of insertion of the frame sections 18 into the channels 34 f and 34 g.

Referring now to FIGS. 7-12, the assembly of the solar panel modules 12 a-12 d using the brackets 30-34 will be described. Initially referring to FIG. 7, one or more brackets 32 may be secured to frame section 18 c of module 12 b. Frame section 18 c thus forms an outer perimeter edge of the array 10. The bracket 32 is secured by first inserting upwardly flaring flange 32 a in channel 22 of the frame section 18 c while the bracket 32 is positioned non-perpendicular to the plane of the outer vertical side surface of the frame section 18 c, as shown in phantom lines in FIG. 7.

As the bracket 32 is rotated clockwise into the position shown in FIG. 7, the flat flange 32 b moves over the lower surface of the frame section 22 so that the longitudinal wall portion 23 enters the channel 32 f. As this happens, the flat flange 32 b flexes downwardly slightly and then barbed edge 32 c engages within the angled notch 26 in the base 24 of the frame section 18 c, thus securing the bracket 32 to the frame section. The longitudinal wall portion 23 contacts the internal shoulder 32 h of the frame section 18 c when the frame section 18 c is fully inserted in the channel 32 f. The curving inner wall 22 a of the intermediate channel 22 and the curving shape of the flange 32 a cooperatively enable this rotational movement to engage the frame section 18 c within the channel 32 f of the bracket 32, and to thus permit the frame section 18 c to be captured within the intermediate channel 22.

Depending on the length of the frame section 18 c, typically two or more brackets 32 will be secured to the frame section 18 c in the above described manner, and then moved slidably along the frame section 18 c to achieve an appropriate spacing from one another that will depend on the overall length of the frame section 18 c. The brackets 32 may then each be secured to the roof 14 via a separate fastener 40, or to some other support structure suitable for supporting the array 10 of the solar panel modules 12. It will also be appreciated that the angled notch 26 and the barbed edge 32 c could be switched so that the barbed edge 32 c is formed on the frame section 18 c and the angled notch 26 is formed as a groove in the flat flange 32 b.

With further reference to FIG. 7, typically a plurality of brackets 30 will be attached to frame section 18 d in the same manner as bracket 32 was attached to frame section 18 c. Again, however, only one bracket 30 is visible in FIG. 7. The brackets 30 may then each be secured via separate fastener, such as fastener 42, to the roof 14 or to other support structure.

Referring to FIG. 8, a plurality of brackets 34 may be secured to frame section 18 b of module 12 b in the manner described above, by positioning the upwardly curving flange 34 a 2 in the channel 22 while the bracket is held at an angle. The bracket 34 may then be rotated downwardly (as described for brackets 30 and 32) until the channel 34 f engages with the frame section 18 b and the barbed edge 34 c engages the angled notch 26 in frame section 18 b. The brackets 34 are preferably spaced apart along the frame section 18 b prior to rotating them into engagement with the frame section 18 b as described above. The brackets 34 attached to the frame section 18 b may then be fastened to the roof 14 or to other support structure via fasteners 44. While not visible in FIG. 8, frame section 18 a, at this point, may have two or more brackets 32 secured to it, and then fastened to the roof 14 or to other support structure via fasteners such as fasteners 44. Frame section 18 a thus forms an outer perimeter section of the array 10 as well.

Referring to FIGS. 7 and 9, module 12 a may then be secured to module 12 b. This is accomplished by angling module 12 a as shown in FIGS. 7 and 9 so that the free upwardly curving flange 30 a engages the channel 22 of frame section 18 c, and then rotating module 12 a counterclockwise in accordance with arrow 50 in FIG. 7. At this point the frame section 18 c of module 12 a and frame section 18 d of module 12 b will be interlocked. Additional brackets 30 may be installed on frame section 18 b of module 12 a, and additional brackets 30 may be installed on frame section 18 d of module 12 a. The brackets 30 of module 12 a may then all be fastened to the separate support base or possibly to roof 14 using fasteners such as fasteners 44. While not shown, it will be appreciated that an additional plurality of brackets 32 may be installed on frame section 18 a. Both of modules 12 a and 12 b will then be fixedly secured to either a support structure or to the roof 14.

At this point module 12 c may be secured to module 12 a. This is accomplished by angling module 12 c as shown in FIG. 10 while inserting the upwardly flaring flange 30 a of each bracket 30 (attached to frame section 18 b of module 12 a) into the channel 22 of frame section 18 a of module 12 c. The module 12 c is then lowered, as indicated by arc 52, so it is positioned parallel to module 12 a. A plurality of brackets 30 may then be attached to frame section 18 c of module 12 c. Additional brackets 30 or 32 may then be secured to frame section 18 b of module 12 c, depending on whether additional modules will be positioned adjacent to frame section 18 b of module 12 c. In this example since only four modules 12 a-12 d are being shown, and since frame section 18 b of module 12 c forms an outer edge of the array 10, this means that no other modules will be positioned along frame section 18 b of module 12 c, so in this example brackets 32 may be used on frame section 18 b of module 12 c. Likewise, since no additional module will be positioned adjacent to frame section 18 d of module 12 c (i.e., frame section 18 d of module 12 c forms an outer edge of the array 10), brackets 32 may be secured to frame section 18 d of module 12 c as well. However, if an additional module was to be secured to frame section 18 d of module 12 c, then brackets 30 would be used on frame section 18 d of module 12 c. Similarly, if an additional module was to be secured adjacent to frame section 18 b of module 12 c, then brackets 30 would be used in place of brackets 32 on frame section 18 b of module 12 c.

Referring now to FIG. 11, the last module 12 d is then secured to modules 12 b and 12 c by first securing frame section 18 d of module 12 d to frame section 18 c of module 12 c. This is done by angling module 12 d as shown in FIG. 11 and engaging the upwardly flaring flange 30 a of each of the brackets 30 that have been attached to frame section 18 c of module 12 c, in the channel 22 of frame section 18 d of module 12 d. Preferably module 12 d is also positioned with a spacing from module 12 b, as it is being secured to module 12 c, so that when module 12 d is lowered its frame section 18 a will clear the brackets 34 attached to frame section 18 b of module 12 b. Module 12 d is then lowered to a position generally parallel to the other modules 12 a, 12 b and 12 c, in accordance with an arc 54, into the position shown in FIG. 12. The module 12 d may then be slid slightly towards frame section 18 b of module 12 b. This causes the frame section 18 a of module 12 d to engage within the channel 34 g of each bracket 34 secured to frame section 18 b of module 12 b. The fully assembled array 10 is shown in FIG. 1. Since the channels 34 attached to frame section 18 b of module 12 b are positioned with flat flanges 34 a 1 facing outwardly, the frame section 18 a of module 12 d fits snugly in the channel 34 g of each bracket 34. When the barbed edge 34 c of each bracket 34 engages the angled notch 26 in the frame section 18 a of module 12 d, then frame section 18 b of module 12 b and frame section 18 a of module 12 d will be fixedly secured together. A plurality of brackets 32 may then be secured to the frame sections 18 b and 18 c of module 12 d, and then secured to roof 14 or to other support structure by fasteners 44. However, in FIGS. 1, 11 and 12, brackets 34 are illustrated as being secured along frame sections 18 b of modules 12 c and 12 d to enable the additional of further modules 12 at a later date.

From the foregoing it will be apparent that the brackets 30, 32 and 34 allow a modularly expandable solar panel array 10 to be formed. The brackets 30, 32 and 34 permit virtually any number of additional solar panel modules 12 to be attached to one another in an X-Y grid of modules. Since the brackets 30, 32 and 34 engage with the channel 22 of each frame section 18 of each module 12, no separate fastening elements are needed to secure each bracket 30, 32 and 34 to its associated frame section 18. This significantly expedites the assembly of the modules 12 a-12 d into the array 10 and reduces the amount and cost of the hardware necessary to install the array on a support base, a roof or other structure.

Another advantage of the array 10 construction described herein is if an array having a given number of modules is initially installed, and then at a later date it is desired to add additional modules to the array, the frame 18 construction and brackets 30, 32 and 34 readily permit such modular expansion. This may involve removing certain ones of the brackets 32 that are positioned along exterior (i.e., exposed) frame sections 18 of the array 10, replacing them with either brackets 30 or 34, and then adding the additional modules 12 in the manner described herein. Likewise, if an array 10 needs to be made smaller at some future time after the array is initially installed, the frame 18 construction and the brackets 30, 32 and 34 enable selected modules 12 of the array 10 to be easily removed.

While various embodiments have been described, those skilled in the art will recognize modifications or variations which might be made without departing from the present disclosure. The examples illustrate the various embodiments and are not intended to limit the present disclosure. Therefore, the description and claims should be interpreted liberally with only such limitation as is necessary in view of the pertinent prior art. 

1. A mounting system for supporting solar panel cells panels above a support surface, the system comprising: a frame including a plurality of frame sections that are secured to a solar panel cell; at least one of the frame sections including: a pair of walls forming a first channel for receiving an edge portion of the solar panel cell; a second channel spaced apart from the first channel, the second channel having a curving inner wall; and a base portion; a mounting bracket having a pair of flanges and forming a third channel therebetween, with one of said flanges forming a curving flange, and wherein said curving flange and said second channel of said frame section cooperatively secure said frame section and said mounting bracket together.
 2. The mounting system of claim 1, wherein said curving flange of said mounting bracket and said curving inner wall of said second channel of said frame section enable said frame section to be positioned non-perpendicular to said mounting bracket, and then rotated about an arc into a position generally perpendicular to said mounting bracket, wherein said curving flange is captured in said second channel.
 3. The mounting system of claim 1, wherein: said frame section includes an angled notch formed in said base portion; and said mounting bracket includes a barbed edge in one of the flanges that engages with the angled notch when the mounting bracket is fully engaged with the frame section.
 4. The mounting system of claim 1, wherein the pair of walls that form the first channel comprise a pair of parallel arranged walls having a thickness generally in accordance with a thickness of the edge portion of the solar panel cell.
 5. The mounting system of claim 1, wherein said mounting bracket further includes a base portion for supporting the mounting bracket on the support surface.
 6. The mounting system of claim 1, wherein the mounting bracket includes an additional pair of flanges extending in a direction opposite to the pair of flanges, the additional pair of flanges forming a fourth channel, with one of the flanges of the additional pair of flanges forming an additional curving flange.
 7. The mounting system of claim 6, wherein the third and fourth channels open facing in opposite directions.
 8. The mounting system of claim 1, wherein the third channel formed in the mounting bracket includes a raised internal shoulder that limits a depth of insertion of the frame section into the third channel.
 9. The mounting bracket of claim 1, wherein the mounting bracket includes an additional pair of flanges extending in a direction opposite to the pair of flanges, the additional pair of flanges forming a fourth channel, with both of the flanges of the additional pair of flanges extending generally parallel to one another.
 10. A mounting system for supporting solar panel cells panels above a support surface, the system comprising: a frame including a plurality of frame sections that are secured to extend around a periphery of a solar panel cell; at least one of the frame sections including: a pair of walls forming a first channel for receiving an edge portion of the solar panel cell; a second channel spaced apart from the first channel, the second channel having a curving inner wall; and a mounting bracket having a curving flange shaped generally in accordance with said curving inner wall, the curving flange and curving inner wall cooperatively enabling the frame to be oriented non-perpendicular to the mounting bracket when the curving flange is initially inserted into the second channel, and then enabling the frame to be rotated into a position generally perpendicular to the mounting bracket.
 11. The mounting system of claim 10, wherein the curving flange is captured within the second channel when the frame is rotated into the perpendicular position relative to the mounting bracket.
 12. The mounting system of claim 10, wherein the mounting bracket includes a generally flat flange that, in connection with the curving flange, forms a third channel.
 13. The mounting system of claim 12, wherein the mounting bracket includes an additional pair of flanges that form a fourth channel, the fourth channel extending generally in a direction opposite that of the third channel.
 14. The mounting system of claim 13, wherein one of the additional pair of flanges of the mounting bracket comprises a curving shape.
 15. The mounting system of claim 13, wherein both of the flanges of the additional pair of flanges of the mounting bracket are formed as generally flat flanges extending parallel to one another.
 16. The mounting system of claim 12, wherein: at least of the flat flange of the mounting bracket and the frame section includes a notch, and the other one of the mounting bracket and the frame section includes a barb shaped to engage with the notch.
 17. A frame adapted to support a solar panel cell, the frame including: a plurality of frame sections adapted to be secured around a perimeter of the solar panel cell, at least one of the frame sections including: a first channel for engaging with an edge portion of the solar panel cell; and a second channel having a curving inner wall for engaging with an external mounting bracket, to thus permit the at least one frame section to be initially engaged with the mounting bracket in an orientation nonperpendicular to the mounting bracket, and then rotated into a position generally perpendicular to the mounting bracket, wherein the mounting bracket is then captured in the second channel.
 18. The frame of claim 17, wherein the first channel and the second channel open in generally different directions.
 19. A mounting bracket for supporting a frame of a solar panel cell above a support surface, the mounting bracket including: a channel having a pair of flanges forming a channel therebetween, wherein the channel receives therein a frame section of the solar panel cell frame when the mounting bracket is coupled to the frame section; and one flange of the pair of flanges having a curving shape that permits the frame section to be engaged in the channel in an orientation non-perpendicular to the mounting bracket, and then pivoted into a position generally perpendicular to the mounting bracket so that the frame section is captured in the channel of the mounting bracket.
 20. The mounting bracket of claim 19, wherein one of the pair of flanges includes a barbed portion for engaging with the frame section when the frame section is fully inserted into the channel of the mounting bracket, to thus help capture the frame section in the channel. 